Oxidation carrier for the oxidation of hydrocarbons



March 4, 1952 c. s. LYNCH ET AL 2,588,260

OXIDATION CARRIER FOR THE OXIDATION OF HYDROCARBONS Original Filed Aug. 12, 1947 2 SHEETS--SHEET 1 March 1952 c. s. LYNCH ET AL 2,588,260

OXIDATION CARRIER FOR THE OXIDATION OF HYDROCARBONS Original Filed Aug. 12, 1947 2 SHEETS -SHEET 2 FIG-2 Patentecl Mar. 4, 1952 OXIDATION CARRIER FOR THE OXIDATION OF HYDROOARBONS Charles S. Lynch, Plainfield, and Eugene S. Corner, Maplewood, N. J., assignors to Standard Oil Development Company, a corporation of Delaware Original application August ,12, 1947, Serial No.

Divided and this application January 26, 1950, Serial No. 140,646

This application is a division of our copending application Serial No. 768,247, filed August 12, 1947, now Patent No. 2,553,551.

The present invention is directed to a method for producing industrial gases containing carbon monoxide and hydrogen from gaseous hydrocarbons and to novel compositions which function as oxygen carriers in the oxidation of gaseous hydrocarbons.

In many industrial processes the raw material is composed of, or essentially contains, a mixture of carbon monoxide and hydrogen. Chief among these processes are the so-called Methanol Synthesis, in which carbon monoxide and hydrogen are reacted in the presence of a suitable catalyst to produce oxygenated organic compounds, and the Fischer Tropsch Synthesis in which carbon monoxide and hydrogen in suitable proportions are reacted in the presence of a suitable catalyst and under selected conditions to produce a product primarily composed of liquid hydrocarbons. In processes of this type it is highly desirable that the feed gas be free from contamination with inert gaseous substances.

The obvious way to obtain a mixture of carbon monoxide and hydrogen is to subject a mixture of a hydrocarbon such as methane and air to controlled combustion. This procedure, however, results in a gas containing a large quantity of nitrogen. This detrimental dilution has led to much study and experimentation, directed toward the development of a method for producing the desired make gas free from contaminants and diluents.

Among the procedures which have been proposed for producing from hydrocarbons a suitable gas mixture containing carbon monoxide and hydrogen free from large volumes of diluent gas is that in which a metal is used as an oxygen carrier. The general procedure proposed is to reactthe hydrocarbon, such as methane, with a metal oxide until the latter is depleted in oxygen content, then to reoxidize the depleted metal carrier with air, venting oh the residue gases and again reacting the regenerated oxide with the hydrocarbon. By this procedure the gas resulting from the reaction of the hydrocarbon with the metal oxide is obtained separately from the gaseous residues from the oxidation of the metal with air.

While a number of metals have been proposed for use in this process they all present difierent problems when it is attempted actually to use them in the process. Zinc oxide is one which theoretically should serve the purpose admirably because its oxidation potential is such that it is 3 Claims. (01. 252-186) practically impossible to oxidize a hydrocarbon with zinc oxide to carbon dioxide whereby a high selectivity to carbon monoxide can be expected in the use of this metal oxide. Zinc oxide,:-however, presents the great difliculty that at the temperature at which it will give up its oxygen the zinc will also vaporizegiving rise to a difiicult recovery problem. Moreover, at the temperature. of operation, zinc oxide does not effect asufilciently high conversion of the hydrocarbon.

Of the many oxides which might be considered useful, iron oxide, based on considerations of availability, price and reactivity with hydrocarbons, would seem to be the logical choice. When it is attempted, however, to react a hydrocarbon such as methane with a fixed bed of iron oxide, the course of the reaction proceedsin a direction quite the contrary of that desired. At the outset the iron oxide oxidizes the hydrocarbon completely to carbon dioxide until an appreciable quantity of free iron is present in the. reaction mass. From that point on some carbon monoxide is produced but at the same time large quantities of carbon are produced by reason of the highly catalytic efiect of the iron on the cracking of hydrocarbons.

It had been expected that this difliculty of controlling the course of the reaction between the hydrocarbons and iron oxide could be ameliorated by operating according to that technique which has come to be known as a fluidized solid technique in which the solid in finely divided form is suspended in a rising stream of the gas to be reacted while correlating the velocityof the gas with respect tothe degree of fineness of the solid to produce a dense suspension of the solid in the gas in which the solid is in a highly turbulent state. The difficulty encountered with this procedure, however, is that when the temperature of operation is maintained within the limits calculated to give the desired rate of re action, for example between about 1600 and 2000 F., the finely divided mixture of iron oxide and iron proves to be very diflicult to fluidize. It

appears that the powdered material becomes sticky in this range of temperatures, although itis considerably below the melting point of either the iron oxide or the iron, with the result that the particles agglomerate and do not remain in the desired state of suspension. This failure to remain fluidized appears to cause the reaction to follow substantially the same course as that oboxide with iron oxide in such manner as to give a very intimate degree of mixing. The intimacy of admixture desired is comparable to that attainable by precipitating the mixed oxides from mixed water solutions of their salts. A comparable degree of mixing for the purpose of the present invention is attainable by soaking either of the oxides in a solution of the salt of the other and thereafter roasting. If desired, one of the oxides can be immersed in the water solution of a salt of the other,-a precipitating agent added to precipitate the oxide of the other, and the resulting solid precipitate filtered, washed and roasted.

The preferred carrier, according to the present invention, is a mixture of F6203 and MnOz containing between and '70 parts by weight of MnOz. The best composition is a 50-50 weight mixture of these compounds. Other iron oxides may be employed, if desired.

The oxygen carrier, according to the present invention, constitutes a marked improvement over iron oxide as an oxygen carrier both in fixed bed operation and in operation according to the so-called fluidized solid technique in which the oxygen carrier in finely divided form is suspended in the form of a dense, turbulent sus-' pension in a rising stream of the hydrocarbon gas. In the fixed bed type of operation the compound oxygen carrier makes possible the realization of a degree of conversion and a selectivity of the reaction toward the production of carbon monoxide and hydrogen unexpectedly superior to that attainable by the use of either component of the compound carrier alone. In the fluidized solid type of operation there is secured, in addition to the foregoing advantages, considerably increased fiuidizability at the temperatures of operation, which are usually between about 1600 F. and 2000 F. It will be understood that the upper limit of thi temperature may be higher and. is dictated only by the melting point of the finely divided solid and the material of which the reaction vessel is made.

Furthermore, the compound carrier makes possible an operation at a high conversion level with high selectivity to carbon monoxide for an extended period of time indicating that there is no critical oxygen content of the compound carrier but that it is efiective over a fairly wide range of oxygen content. This isimportant commercially because in a two-stage operation, in one stage of which the hydrocarbon is reacted with the oxygen carrier and in the other stage of which the oxygen content of the carrier is replenished by treatment with an oxidizing agent such as air, much less careful control is required in both stages. Finally it is to be observed that the foregoing advantages are realized in both fixed bed and fluidized solid operations with a minimum production of carbon.

In one particular embodiment of the present invention, namely that in which the fluidized solid technique is employed, the fiuidizing character of the solid is improved by incorporating in it varying amounts of magnesia and/or chromium oxide which may be included in the composition of the oxygen carrier by 'coprecipitation with the components of the carrier. From 10 to 40% by weight of the magnesia and/or chromium oxide may be advantageously included in the composition to improve fiuidiz in'g characteristics and in some instances to improve conversion and selectivity.

The nature of the present invention will be more fully understood from the following detailed description of the accompanying drawing in which:

Fig. 1 is a front elevation in diagrammatic form of one type of apparatus suitable for the practice of the present invention;

Fig. 2 is a pair of curves showing the relationship between hydrocarbon conversion and selectivity to carbon monoxide with compound carriers according to the present invention with varying contents of manganese oxide; and

Fig. 3 is a family of curves showing the variation in selectivity of a 5-05O mixture of iron oxide and manganese oxide with time of operation.

Referring to the drawing in detail, numeral l designates a reaction vessel and numeral 2 designates a regeneration vessel. In the embodiment shown these vessels operate on the dense phase drawofi principle. It will be understood that these vessels can be of the well known bottom drawofi' type or the strictly upfiow type.

Vessel i is provided at its bottom with an inlet 2' for gas and finely divided solid and at its upper end with an outlet 3 for gas, ahead of which is an internal cyclone 4 or other separator for gases and solids having a dip leg 5 depending into the vessel. On one wall the vessel is provided with a duct 6 having its open upper end terminating at the selected level for the dense phase of the suspension. This duct empties into a line 7 into which air or other oxidizing gas is fed through line 8. Line I discharges into the bottom of vessel 2 which, like vessel 1, is provided at its upper end with a gas vent 9 ahead of which is arranged a cyclone separator I0 having a dip leg H extending into the dense phase of the suspension in vessel 2. Vessel 2 is also provided with a duct I2 on one of its walls having its open upper end located at the intended level of the dense phase of the suspension in vessel 2. Duct I2 empties into line 2' into which is fed a hydrocarbon gas through line I3.

In carrying out the process of the present invention in the apparatus described, the vessels are charged. with finely divided solid the individual particles of which are an intimate mixture of manganese oxide and iron oxide with or without other fiuidizing additions. As previously indicated, this mixture is conveniently prepared by mixing aqueous solutions of a manganese salt and an iron salt and coprecipitating the hydroxides with an alkali. The precipitate is carefully washed to remove water-soluble contaminants after which it is dried and roasted. If the final product is not in the finely divided form heretofore specified, it is ground so as to satisfy the requirements.

In starting up with both vessels charged with the finely divided solid mentioned above, the system may be brought to a temperature between about 1550 and 1850 F. by feeding hot combustion gases through lines 8 and I3. If desired, some finely divided carbon may be mixed with the initial charge and the system brought to temperature by burning off the carbon. When the operating temperature is obtained, a hydrocarbon gas is fed through line I3 at a velocity such as to maintain the finely divided solid in vessel I in suspension in the gas in the form of a dense body in which the particles are in incessant motion. The velocity should be so regulated as to produce a suspension having at least about 5% by volume of solids, preferably be tween about 1-0 and 25%. The velocity is correlated with the amount of solids charged so as to bring the level of the dense phase to a point where it overflows into conduit 6. The gases passing out of the vessel tend to carry solids with them. These solids are separated in the cyclone A and returned to the dense suspension.

As the solid overflows into conduit 6 and thus into line i, preheated air or other oxidizing medium is fed in through line 8 at a velocity such as to carry the finely divided solid into vessel 2 and maintain it therein in a suspension of the character heretofore described, the level of the dense phase of the suspension being so regulated that the dense phase overflows into conduit [2 which carries solid back into line 2'.

The heat required for the reaction in vessel l is supplied primarily as sensible heat contained in the solids returned from vessel 2 supplemented by preheat imparted to the hydrocarbon gas from the hot exhaust gas from vessel 2.

It will be appreciated that the illustration of the apparatus and the drawing is limited to the bare essentials, calculated merely to depict the flow plan of the process. Design and engineering details are purposely omitted to avoid unnecessary complication. Among such details are heat exchangers, aerating jets for the various conduits, pumps, and the like. It is repeated that the flow plan shown is only one of several which may be used, the essential requirement 100 v./v./hr. with compound carriers accrd ing to the present invention with varying contents of manganese oxide. Curve B shows the variation in selectivity to CO under the same conditions with the same variations in content of MnOz. The data on the runs on which these curves are based are as follows:

Methane oxidation with FeaOa-MnOz compositions [Fixed bed; l700 F.; 100 v./v./hour.]

MnOz Content, Weight per cent 0 7 10 50 90 100 Methane Conversion, per cent 56 70 90 32 22 Selectivity, Mol per cent:

. CO 22 70 75 95 82 CO2 78 30 25 .8 .l 0 0 0 0 It will be observed that under the conditions of operation iron oxide alone gave a conversion of 56% with a selectivity to C0 of 22%. 10% of manganese oxide increased the conversion to 70% and the selectivity to 70%. Maximum conversion was obtained with a 50-50 mixture of iron oxide and manganese oxide with a selectivity to C0 of 75%. As the iron oxide decreased below 50% the selectivity tended to rise but the conversion fell off rapidly. Manganese oxide alone gave a conversion of only 22%. It will be apparent that over a wide variation of composition both conversion and selectivity were maintained at a high level.

Referring to Fig. 3, curve C shows the variation of selectivity to carbon monoxide with time on stream when using a 50-50 mixture of F820:

and MnOz in a fixed bed reactor at 1700 F. with Methane oxidation with 50F62O3-50MI1O2 [Fixed bed; 1700 F.; 100 v./v./hr.]

Time on Steam, Min 15 30 Methane Conversion, per cent 100 94 98 Selectivity, M01 per cent:

00 .l 1 72 76 66 CO1 99 23 24 18 0 0 0 16 It will be observed first of all that there is a relatively short induction period in which product gas changes from 100% C02 to a relatively high percentage of CO. This high selectivity to C0 persisted in the particular operation described for a period of about 25 minutes when it began to drop off simultaneously with the formation'of carbon as shown in curve E. This period of high selectivity to CO with no carbon formation indicates the high degree of utility of the oxygen carrier for commercial operations. In a continuous operation as heretofore described it is relatively easy to operate so as to limit the residence time of the oxygen carrier in the methane conversion zone to less than 25 minutes. A Wide variation in residence time is permissible without any substantial efiect on the composition of the product gas and without any formation of carbon. This, of course, indicates that the oxygen carrier is effective in producing the desired results over a wide range of oxygen content in the carrier. Thus, with the use of the oxygen carrier in the present invention much less careful control of residence time of the carrier in the reactor and the degree of reoxidation of the carrier in the regenerating zone is required.

In order to demonstrate the eiiectiveness of the composite carrier in a fluidized type operation, a 50-50 mixture of FO2O3 and MnOz prepared by impregnation of F6203 with a water solution of manganese nitrate followed by drying and calcining of the impregnated iron oxide was employed in finely divided form in a fluidized operation in which methane was oxidized. In this operation the finely divided solid was continuously maintained in the reaction zone, the velocity of the methane upwardly through the mass of finely divided solid being sufficient to maintain the finely divided material in a dense turbulent suspension. The reaction zone was maintained at a temperature of 1700 F. and the feed rate of the methane was regulated at a value of 200 v./v./hr. The date obtained were as follows:

Methane oxidation with 50 FezOa-SOMnOz [Fluid bed operation; 1700 F.; 200 v./v./hr.]

1 Good. Channeling observed.

In this operation it will be observed that high selectivity was maintained to the end of the run, which was 45 minutes in duration. Furthermore,

ituwill be observed that no. carbon; formation had begun" atthe end-of the run. After: 35 minutes of operation; the fiuidization, which. up to that time-had been excellent, began to show signs of impairment as indicated. by the tell-tale occurrence-of channeling: It will'be understood, however, that in a continuous operation of. the type illustrated in the drawing the residence time of the oxygen carrier in the reaction zone can readily be controlled so as to be less than 45 minutes. The channeling was presumably due to decrease in oxygen'content of the carrier below the desired level. The important fact revealed by this data isthat the oxygen carrier of the present invention performs better in the fluidized type of operation than in a fixed bed type of operation.

In order to illustrate the nature of the improvement effected. by the joint use of magnesia or chromium oxide with the. iron: oxide-mark ganese oxide carrier, runs were made employing the fluidized solid technique with three-com. ponent carriers of: these types. In. the'following table are. given theoperating conditions and the results:

[200 v-./v./hr.; 1 quartz reactor; fluidbed operation] 3 38 F920 45 FezOa- 45 FCzOa OxideGompcsition 45 MnO 45 MnOr 45 M1102- l7 DigO l h1g0 l0 C1203 Time on Stream,

Min r 54 G2 71 4.3 50 62 29 Methane Conversion,

per cent. 56 83 94 62 73 91 Selectivity, Mel per cent:

CO Q0 90' 89 89 90 91 88 C02 1." l0 l0 8 ll 9 17 C 0 O 3 0 0 I) 0 These data indicate that excellent results can be obtained by the utilization of these three component mixtures. Both the methane conversion and selectivity were high and carbon. formation did not occur over. long periods of operation. These oxygen carriers gave the best results thus far attainable in an operation of this type.

Although in the foregoing the specific opera.- tion described employs the'fluidized solids technique, it is to be'understood that in. the practice. of the present inventiona fixed bed or a combination of fixed bed and afluidized solid bed may be employed. In general, the temperature in the. hydrocarbon oxidation zone is maintainedv in the range between about 1600" F. and 2000? F. The pressure may be atmospheric or superatmospheric, depending on design and economic considerations. Pressures as high as 600 lbs/sq. in. are contemplated. The feed rate of the hydro.- carbon gas. mayvarywidely, depending on other operating conditions. In general, permissible feedrates will be higher the-higher the operat-- ing temperature and pressure. Feed rates as ratemay be as high as 3000 v./v./hr. The residence time of the oxygen carrier inthe hydrocarbon oxidation zone Will vary and is afunce tion of the circulation rates required for temperature control between the reactor and the regenerator. This residence time is also a function of the average oxygen to metal ratio in the oxygen carrier at which high selectivities for CO production are obtained. This residence time may vary from about 5 to 30 minutes. In general, it is preferred to have aresidence time of the oxygen carrier in the hydrocarbon oxidation zone in the range of about 10 to 15 minutes.

The nature and objects of. the present invention having been described and illustrated, what is claimed as new and useful and is. desired to be secured by Letters Patent is:

1. An oxygen carrier for the oxidation of hydro-- carbons to a gas containing carbon monoxide and hydrogen. consisting essentially of approximatelyequal gravimetric proportions of iron oxide and manganese oxide and also containing about 10 to 40 weight per cent of a metal oxide selected from the classconsisting of magnesia and chromium oxide, compounded by coprecipitation of thesaid oxides from mixed aqueous solutions of their salts.

2; An' oxygen carrier adapted to oxidizehydrocarbons to a gas containing carbon monoxide and hydrogen consisting essentiallyof approximately equal gravimetric proportions of iron oxide and manganese oxide and also containing about 10 weight per cent of magnesia, based on the total.

catalyst.

3. An oxygen carrier adapted to oxidize hydro-- carbons to a gas containing carbon monoxide REFERENCES CITED The following references are of record in the file of this patentr UNITED STATES PATENTS Number Name Date 2,180,672 Frey Nov. 21, 1939 2,258,111 Engel Oct. '7, 1941 

1. AN OXYGEN CARRIER FOR THE OXIDATION OF HYDROCARBONS TO A GAS CONTAINING CARBON MONOXIDE AND HYDROGEN CONSISTING ESSENTIALLY OF APPROXIMATELY EQUAL GRAVIMETRIC PROPORTIONS OF IRON OXIDE AND MANGANESE OXIDE AND ALSO CONTAINING ABOUT 10 TO 40 WEIGHT PER CENT OF A METAL OXIDE SELECTED FROM THE CLAS CONSISTING OF MAGNESIA AND CHROMIUM OXIDE, COMPOUNDED BY COPRECIPITATION OF THE SAID OXIDES FROM MIXED AQUEOUS SOLUTIONS OF THEIR SALTS. 